Roofing-felt.



R. P. PERRY.

ROOFING FELT.

APPLICATION HLED SEPT. 29. 1917.

Patented Apr. 29, 1915).

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MTE@ STAS PATENT @FlllilEo nar r. PERRY, or UPPER MONTCLAIR, NEW JEnsnYj assreivon 'ro rnnnananrr COMPANY, A CORPORATION OF WEST VIRGINIA.

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asoaeoa l Specification of Letters Patent.

Application filed September 29, 1917. Serial No.'193,985.

. ln the parent application have disclosed a method of making felts or papers adapted t be used, for example, in making so-called tarred or asphalt `saturated felts, or for making prepared rooiings of various classes such as the so-called rubber roofings of commerce. lin the above entitled application l have claimed broadly such felts and the processes of making the same wherein is employed a waterproofing material in comminuted form, especially in the form .of fine hairs, threads or filaments, and ll have specifically claimed that form of my linvention wherein l employ pitch as the waterproofing material.

While pitch has many advantages in Athis connection, for certain purposes l prefer to use a resinous material, such as rosin, as the waterproofing material, this material possessing valuable characteristics for certain uses.

The object of my invention is to manufacture a substitute for the so-called dryfelts previously used in the manufacture of roofing materials such as the rubber roofings ,previously referred to, which shall be cheaper and more convenient to manufacture, and shall already contain a predetermined amount of comminuted resinous material in solid form. The product of my invention may be open and porous suiiiciently to permit saturation, and has other desirable properties subsequently to be described.

My process briefly stated-comprises adding to the usual watery pulp of beaten rags or paper or a mixture of the two, or other fibrous or paper-making material in the form of a watery pulp,a predetermined amount of subdivided or comminuted resinous material, in solid form, preferably rosin. Various resinous materials, such as rosin, paracumarone, and bakelite, may be employed wlth advantage and ll intend that all of the materials known tothe trade as resinous materials, such as rosin, shall be comprehended within the spirit of my invention as expressed in the claims. Such resinous materials, as rosin, are readily .fusible and of a waterproofing and weather-resisting nature. By the term comminuted as usedin the specification and claims I mean to designate that the waterproofing material is in the form of small particles or Patented Apr. 29, 19190 pieces 0f any desiredv form. l prefer, howf ever, to use such material in the form of hairs or filaments as described in my copending application filed March 27, 1917, bearing Serial "No, 157,752, and entitled Bituminous materials in filamentary form, and processesyand apparatus for making the same. v'Such filaments may be of varying length and often are broken into fragments, and I, therefore, intend that the term fila- "ment as used in the specification and claims -shall include long or short filaments or frag- Y ments of the salne. of the predetermined amount of comminuted material is made while the watery pulp or paper stock is still in the beater. The mixture of comminuted y material and watery pulp is worked in the beater long enough to bring about a substantially uniform mixture of the materials present in the beater. The mixture is later fed at a predetermined rate into the paper-forming vat where said mixture is formed in the usual manner into a sheet or layer, which may then be dried in the manner common lin the manufacture of papers and felts. While any of the materials known to the trade as resinous materials may be employedv with success in my process "for the production of the product of my invention, lf prefer to use the resinous material known as rosin, for the reason that -in the manufacture of felts of the character disclosed in my co-pending application bearing Serial No. 161,670, it is often desirable to produce a light colored waterproofed felt, and for such a purpose rosin is particularly desirable since this material when in comminuted form, especially when in the form of fine hairs, threads, 0r filaments, is light in color so that the resulting felt is correspondingly of a light color. A The mixture of comminuted resinous material and the watery pulp of paper stock is worked in the beater lon about a substantially uni orm mixture o Preferably the addition enough to bring the materials present in the beater.` The mixture is later fed at a,predetermined rate into the'paper-formin'g vat or tank, where, by means of the usual woolen blanket or wet felt and the usual couche roll passing over the usual perforated brass or other cylinder, the mixture of pulp fand comminuted resinous material is formed into a sheet 0r layer which may then be dried in the manner-'common in the manufacture of papers and felts.

The paper stock may consist entirely of rags, or entirely of paper, or of a mixture of rags and paper in any desired proportion, or other animal, vegetable or mineral fibrous material, in any desired proportions, alone or in combination with various fillers or substitutes. I have found that as a result of the additionpf the solid comminuted resinous material I may use a larger proportion of paper 0r other so-called hard stock and 'a smaller proportion of rags orsoft stock than has hitherto been deemed feasible, and still leave the resulting sheet open and porous enough to absorb the desired amount of saturating or waterproofing material dury ingthe subsequent saturating step.

eferring to the drawing wherein I have illustrated diagrammatically,` a device for making the product and practising the process of my invention,

1 shows diagrammatically the usual beater for disintegrating rags, papers or other paper stock to be used in the manufacture of my felt. rIhe stock S is disintegrated between the bed plate 2 andthe rotary cutting member 3, the operation resulting in a circula tion of the watery pulp within the beater. Generally the beating operation requires from one-half to two hours to complete, dependent upon the character of stock used to make the felt. A short while before the disintegration of the paper stock is complete, generally about 5 to 20 minutes before the fibrous stock is completely disintegrated, I add to the pulp in the beater a predetermined quantity Aof comminuted resinous material in solid form.` The beater is kept in operation after such addition until the pul and resinous material are substantially unlformly intermixed.

When the mixture is complete, it is dropped into the beater chest or storage tank, and is later transferred to the rifiiers and screens which remove foreign material and lumps of fibrous material which have not been suiiciently disintegrated or pulped, and passes to the cylinder vat 6 where the sheet of felt or paper is formed. i

Within the cylinder vat 6 rotates the screen cylinder mold 7 of the type usual in the paper-making industry. A difference in hydrostatic level between the interior and the exterior of the cylinder produces a suction and draws the water through the perforations of the screen on the periphery of the cylinder mold, causing a layer 11 of pulp to be formed. This layer l1, consisting 'of a substantially uniform mixture of comminuted resinous materiall in solid form and watery pulpypaper-forming stock, is picked od by the so-called wet felt? or woolen blanket endlessv belt 12', which passes underthe couche roll 8 and by it is pressed against the layer 11 whichthen adheres to the wet felt 12 as a sheet of felt or paper 13 traveling as indicated by the arrow. In its travel it may pass over one or more suction boxes, as shown at 14, and below a press roll 15, which remove some ofthe `water from the sheet 13 and mat it together sufficiently so that it now can be led to the series of revolving drier rolls 10 which are steamheated, and serve to evaporate most of the waterin the sheet 13. A sufficient number of driers are used so that by the time the sheet 13 has passed over all of them it becomes a substantially dry sheet of paper or felt, and is wound into rolls, or otherwise disposed of for use or for shipment.

If desired, the dryingaction may be continued so long and 'at such a temperature that ra slight softening or fusing of the comminuted resinous material in solid form takes place, whereby a sort of cementing action is brought about causing the sheet to be strengthened and rendered more rcoherent.

While any form of comminuted or subi' lll@ While any desired proportions of the various ingredients used in making my felt may be employed, I prefer to use between 10% and 90% by weight of comminuted resinous material, the remainder consisting of paper stock. While any composition or kind of paper stock may be employed, I prefer to use a mixture of rags and old paper in about equal proportions by weight, though these proportions may be varied at will.

While I have described the comminuted or subdivided solid resinous material as being added to the paper stock while in the beaters, and while this will ordinarily'be the preferred practice, it may be desirable,

1n some cases, to introduce the resinous material to thebeaters in comparatively large masses or pieces. These relatively large masses are subdivided or comminuted b the action of the beater, and the desired mixture is thus obtained. It is immaterial forthe purposes of my invention just how the resinous material is introduced,'s0 long as it is finally obtained in the comminuted or subdivided form mixed With and dis-` tributed throughout the watery pulpy stock Which is used to form the sheet of felt or paper, ortis distributed in such form on or through such sheet. n

The sheet so formed may, if desired, be saturated With any liquid or molten Waterproofing material.

What I claim is.'

1. As an article of manufacture, a'porous, flexible, sheet of construction material consisting of relatively large particles of resinous material and other material 2. As an article of manufacture, a porous,

fieXible body comprising particles of rosin in solid comminuted form 0f appreciable size and fibrous material.

3. As an article of manufacture, a body comprising resinous material in iilamentary form and disintegrated paper stock material..

4. As an article of manufacture, a construction material consisting of a felted mass of rosin in the form of filaments and other material.

5. As an article of manufacture, a construction material comprising a felted mass of mixed comminuted rosin in solid filamentary form and disintegrated paper stock.

6. As anarticle of manufacture, a construction material comprising a felted mass of rosin filaments and fibrous material, impregnated With a Waterproofing material.

In testimony whereof l afliX my signature.

RAY P. PERRY. 

